Emerging Paradigms in Self-Assembled and Architected Scaffolds: AI-Augmented Hierarchical Design, Advanced Synthesis and Engineering Applications

Dear Colleagues,

The paradigm of structural materials science is shifting from monolithic bulk solids to self-assembled and architected porous structures. The ability to manipulate the internal architecture of materials (metals and alloys, ceramics and glasses, polymers, composites, semiconductors and carbon-based materials) at the micro- and nano-scales has opened unprecedented avenues for property optimization. By designing complex porous geometries, ranging from stochastic foams to mathematically defined triply periodic minimal surfaces (TPMSs) such as gyroids and diamond lattices, researchers can now decouple strength, density, and functionality. This research area is currently fueled by varied advanced fabrication techniques, encompassing sophisticated additive manufacturing (AM) and precision laser processing, alongside traditional yet continuously evolving physical and chemical methods such as electrochemical dealloying (ECD), liquid metal dealloying (LMD), etc. Furthermore, the integration of artificial intelligence (AI), in particular machine learning (ML) and deep learning (DL), has revolutionized the way we predict mechanical responses, optimize topology, and simulate the electrochemical behavior of these materials. As industries continue to demand lightweight, high-energy-density, and biocompatible solutions, the scientific community is making rapid strides in exploring porous metallic systems derived from traditional stainless steels, superalloys, smart materials, amorphous systems, multicomponent and medium-/high-entropy alloys, and biomaterials. We welcome contributions demonstrating how AI-driven topology optimization can solve cross-disciplinary challenges, such as designing lightweight components for aerospace, developing novel vibration-damping systems for maritime engineering, and engineering high-efficiency heat exchangers for heavy machinery and energy storage sectors. The scope of this Special Issue encompasses the full spectrum of material design, ranging from bottom-up self-assembled systems that rely on thermodynamic phase separation and chemical dealloying to top-down architected scaffolds driven by AI-augmented additive manufacturing and topology optimization.

This Special Issue will provide a comprehensive, multi-disciplinary platform for sharing the latest breakthroughs in the synthesis, characterization, and application of self-assembled and architected porous structures. It will bridge the gap between fundamental materials science and practical engineering applications. The scope of this Special Issue is broad, covering varied materials and fabrication approaches, ranging from cutting-edge additive manufacturing processes to established dealloying methodologies and emerging templating strategies. We specifically encourage submissions that explore the synergy between material composition and the resulting architectural properties. Furthermore, we will highlight the role of AI in “materials-by-design”, utilizing generative algorithms to create structures that maximize energy absorption, mass transport, or osseointegration. This Special Issue will compile knowledge critical for researchers working at the intersection of materials science and engineering, AI-driven design and robotics, energy storage and electronics, and biomedical and mobility applications.

In this Special Issue, original research articles and reviews are welcome. Research areas may include (but are not limited to) the following:

Functional Material Platforms for Engineered Porosity:

• Metallic systems: stainless steels (austenitic, ferritic, martensitic), superalloys (Ni-, Co-, FeNi-based), multicomponent, and medium-/high-entropy alloys (M-HEAs);
• Ceramics, glasses, and glass-ceramics: bioactive glasses (BAGs), bulk metallic glasses (BMGs), chalcogenide glasses, sol–gel glasses (SGGs), and traditional glass-ceramics (GCs);
• Polymers and composites, with a focus on smart materials, including shape memory alloys (SMAs), magnetostrictive materials (MSMs), electroactive polymers (EAPs), self-healing polymers (SHPs), phase change materials (PCMs), stimuli-responsive hydrogels (SRHs), and photo-/thermo-chromic materials (PCMs/TCMs);
• Semiconductors and carbon-based materials.

Advanced Scaffold Design Principles:

• Design, synthesis, and characterization of self-assembled porous structures, including those formed via thermodynamic phase separation, chemical dealloying, or templating;
• Additive manufacturing and analysis of architected materials with complex geometries, such as stochastic foams and mathematically defined triply periodic minimal surfaces (TPMSs), including gyroids and diamond lattices;
• Multi-scale manipulation of internal material architecture for precision property optimization;
• Algorithmic and mathematical approaches to defining novel porous geometries.

AI-Augmented Hierarchical Design:

• AI-driven topology optimization for designing lightweight, functional, and efficient porous structures across disciplines;
• Application of machine learning (ML) and deep learning (DL) for predicting mechanical responses, simulating electrochemical behavior, and understanding structure–property relationships;
• Generative algorithms and inverse design approaches for “materials-by-design” of porous systems with target properties;
• AI-augmented workflows in additive manufacturing and process control for porous materials;
• Development of computational models and simulation tools leveraging AI for performance prediction and optimization.

Smart Synthesis Approaches:

• Advanced additive manufacturing (AM) techniques (VPP, SL, MEX, PBF, BJ, DED, MJ) for precise architectural control;
• Precision laser processing and other subtractive or formative manufacturing approaches;
• Physical and chemical synthesis methods, especially advanced dealloying techniques such as electrochemical dealloying (ECD) and liquid metal dealloying (LMD);
• Emerging templating strategies (colloidal and other forms of sacrificial templating) and bottom-up assembly processes.

Multifunctional Performance:

• Strategies for decoupling conflicting material properties such as strength, stiffness, density, and energy absorption;
• Designing porous structures for enhanced energy absorption, impact resistance, and crashworthiness;
• Optimizing porous architectures for mass transport, surface area, and catalytic activity;
• Tailoring thermal management properties, including high-efficiency heat exchangers and thermal insulation.

Interdisciplinary Application Frontiers:

• Lightweight component design for aerospace, automotive, and mobility sectors demanding high strength-to-weight ratios;
• Development of novel vibration-damping, shock absorption, and acoustic insulation systems for maritime, civil, and mechanical engineering;
• Porous materials for advanced energy storage solutions (electrodes for batteries and supercapacitors);
• Biomaterials and biomedical applications: metallic lattices for orthopedic load-bearing implants, polymeric and ceramic scaffolds for tissue engineering and bone regeneration, and biocompatible porous architectures;
• Integration of porous structures in electronics, sensors, actuators, and other functional devices.

Science–Engineering Nexus:

• Investigating the critical synergy between material composition, internal architecture, fabrication method, and macroscopic performance;
• Translating fundamental scientific breakthroughs in the understanding of porous materials into tangible engineering solutions and products;
• Integrating bottom-up self-assembly principles with top-down architected design approaches to create novel materials.

We look forward to receiving your contributions.

Dr. Artem Okulov
Prof. Dr. Bin Zhang
Prof. Dr. Dawei Yu
Prof. Dr. Yufan Zhao
Dr. Zaijiu Li
Guest Editors

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• additive manufacturing
• liquid metal dealloying
• topology optimization
• artificial intelligence
• self-assembled porous structures
• architected scaffolds
• triply periodic minimal surfaces
• high-entropy alloys
• biomedical applications
• energy storage and electronics